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BEAR Power 
                Supplies custom featuresCustom Power Supplies

Rugged power converters made in the USA to your specifications

BEAR excels at custom power supply design and manufacturing. We specialize in meeting your most unusual requirements: hard-to-meet electrical specs, unusual features or form factors, very long life or extreme operating temperature ranges, or whatever you can throw at us. Try us!

From mW to KW, we create AC/DC, DC/AC or DC/DC converters in open frame, enclosed or encapsulated packages to suit your needs.

Our custom power converters are compact and rugged. They are designed and built for long life and reliable operation over a wide operating temperature range.

BEAR custom power supplies are used in a wide range of industrial, commercial and medical applications including telecommunications, smart grid, military, transportation, industrial automation and portable systems. 

Why work with BEAR?

First: Expertise. We understand how to make rugged, reliable power supplies.

Second: We're easy to work with. Our engineering and manufacturing teams work together in one location, conveniently located in western New York. We focus on understanding your real needs, offering expert guidance on your specs, and creating highly manufacturable products.

You'll go from concept to prototype to production -- quickly and cost effectively -- without the communication issues and delays you can experience with offshore manufacturers.

Our NRE charges are reasonable, and we'll take on custom power supply jobs with lower production volumes than many other suppliers. We currently produce custom power supplies in quantities from 50 to 50 thousand per year in our upstate New York manufacturing center.

Designed and made in the USA.

What can we do for you?

Thinking of using a custom power supply? Browse the gallery below for a few examples that show how a custom power supply made sense to meet unusual OEM requirements. 

Then give us a call. We'll help you weigh the benefits of using a custom power supply in your project. We'll tell you right up front if you'd be better off using a standard power supply, and why. Contact us directly or use our online custom power supply RFQ form to get started.

 BEAR custom power supply gallery

 

50 Watt DC/AC industrial power supply

  • Input 40-90 V DC
  • 16 kHz AC output
  • 1 A output

This high-frequency transformer driver for floating supplies is used with 3-phase industrial motors, meeting the customer's unusual requirements for input, output and frequency. The compact, rugged design measures 3.5 x 2 x 1 inch and features a wide operating temperature range.

 

75 Watt dual-output AC/DC medical power supply

  • CF rated medical power supply
  • Ultra-low capacitance < 15 pF
  • Separate BF rated input

This 75 Watt medical power supply powers a surgical instrument. The CF-rated output features an ultra-low capacitance of less than 15 pF. The two outputs can be controlled independently so that the CF-rated output can be switched off when not needed, while the BF-rated output remains active to supply electronics used in the vicinity of a patient. The 8 x 2.5 x 1.25 inch universal-input medical power supply has very low EMI and is certified to EN 60601-1-2 (revision 2 and revision 3).

 

40 Watt AC/DC medical power supply

  • CF rated medical power supply
  • super-capacitor powered alarm circuit

This 40 Watt medical power supply is used in a life support system. It features a super capacitor powered alarm circuit to notify users if the the unit becomes unplugged or loses power. 

  "BEAR employees are great to work with and very responsive to my needs."

- Bob Lindley, Hardware Design Engineer
Sensis Corporation

15 Watt DC/DC power supply for specialty lighting

  • high voltage arc (12,000 V) to start lamp
  • switches to constant power to run bulb
  • 12 to 24 VDC input

This highly efficient converter for specialty lighting applications delivers a high-voltage arc to start an arc lamp, then switches to a constant power mode for long-term operation. It accepts an input range of 12 to 24 VDC.

75 Watt combination AC/DC and AC/AC medical power supply

  • universal input
  • 1 AC output (120 VAC)
  • 4 DC outputs (+24 VDC, +12 VDC, +5 VDC, +5 VDC isolated)

This power converter has universal input and five different outputs for AC, DC and isolated DC voltages. It powers a multi-function medical diagnostic system that is compact and portable.

 

15 Watt DC/DC medical power supply

  • drives a 15 Watt LED with dimming
  • drives variable-speed fan to maintain temperature
  • compact 1 x 3" size

This compact, dual-purpose medical power supply drives a 15 Watt LED with dimming. It also powers a variable-speed fan to prevent LED overheating. The microprocessor reads a temperature sensor on the LED and automatically adjusts fan speed to maintain the temperature below the set threshold. 

 

 

BEAR custom power supply production capabilities include fast-turn prototypes, pre-production runs, and low- to mid-volume manufacturing in our USA facility. 

 

12 Watt AC/DC power supply for medical

  • plugs directly into wall outlet
  • rugged: very rigorous drop test; built to withstand pulling, yanking and impact
  • production volume several hundred thousand/year

This rugged "wall wart" power supply was designed for the rigors of a hospital-based use. It withstands abuse such as being yanked from the wall and slammed onto the floor. The sealed and molded package can be disinfected and washed down with chemicals.

3 Watt DC/DC power supply for LED lighting

  • very small
  • incorporates microprocessor for dimming
  • high efficiency

This compact DC/DC converter is used in a hand-held LED device and incorporates an LED dimming function in a very compact size.

 

"Working with BEAR’s USA-based design and manufacturing team is a plus. They anticipated our needs, made excellent design recommendations, and provided fast turn-around."

- Bob Cook, president
Velocite Systems

BEAR custom power supply for industrial monitoring

75 Watt AC/DC power supply for industrial monitoring

  • dual input: universal AC plus 24 VDC
  • -40 to +70C full-load operating temperature
  • reports output current, output voltage and temperature over I2C

This dual-input power supply allows an industrial system to run on AC with auxiliary DC input. The self-monitoring feature allows the system to query the supply’s functioning over an I2C bus. As part of an outdoor transportable measurement system, it features a wide full-load temperature and high vibration tolerance.

BEAR custom power supply for military use

15 KV, 5 Watt DC/DC converter for military

  • 15,000 Volt output
  • triple outputs, low ripple
  • mil spec for shock and vibe

This rugged, triple-output power supply features extremely high output voltage. Designed for an airborne military application, the compact converter is encapsulated in a die-cast aluminum housing and meets mil specs for shock and vibration.

 

"We're pleased to be working with [BEAR parent company] Z-AXIS, which was highly recommended by other groups within Harris for its quality and on-time delivery."

- Thomas Kenny, vice president of product line management
Harris RF Communications

BEAR custom power supply for utility monitoring

30 Watt AC/DC power supply for utilities

  • extreme operating temperature range
  • high line surge capacity
  • long life

As part of a monitoring system to be mounted on a utility pole, this power supply will deliver years of reliable operation under extreme temperatures. It will also withstand high transient surges such as those caused by lightning.

BEAR 660 W custom AC/DC power supply CF rated

660 Watt AC/DC power supply ultra-low leakage current for medical instruments

  • very low leakage current (5 µA) exceeds standards for Type CF medical equipment
  • 3 isolated outputs
  • universal input with PFC front end

This custom medical power supply includes a unique "self-monitoring" feature with built-in digital reporting of output voltages, current and operating temperatures. See more information about our medical power supplies.

 

BEAR designs and manufactures custom power supplies for a wide range of medical, commercial and industrial applications. 

 

BEAR 180 watt custom power supply for ground transportation

180 Watt custom DC/DC converter for ground transportation instrument

  • 4,000 VAC input/output isolation
  • very long life
  • low input and output noise

Designed to meet a requirement for extremely high input/output isolation, this custom DC/DC converter also allowed our customer to reduce the size and cost of their existing system.

BEAR 850 Watt custom DC/DC converter


 

850 Watt custom DC/DC converter for mobile communications system

  • 3 isolated outputs
  • hot-swappable with load sharing
  • stringent mechanical constraints

Rugged custom design with specific mechanical constraints is used in a rack-mounted system in a mobile communications unit.

 

With custom power supply design, manufacturing, sales and support all under one roof, BEAR offers unique advantages in design for manufacturing (DFM), quality and customer support.

 

BEAR rack-mounted custom power supply for transportation

Rack-mounted AC/DC converter for transportation systems

  • PFC input / 60W output
  • Minimum 10-year life required
  • 24/7 operation in a fanless system
  • Custom mechanical design

This customer required very high reliability and long life. They also had specific mechanical configuration and input connector requirements.

BEAR custom 300W DC/DC converter for telecom

300 Watt DC/DC converter for commercial telecom system

  • Four different outputs
  • Input - 48VDC
  • High efficiency

High efficiency allows this unit to be cooled with a single fan. It replaced an off-shore manufacturer’s power supply that is less efficient and required two large cooling fans. BEAR's mechanical design recommendations allowed our customer to remove other hardware costs from their system.

 

"From the initial call, the customer was very impressed with BEAR’s knowledge and support for custom power supply design."

– Perry Thornton, sales representative
Pinnacle Marketing

BEAR 60W custom power supply for medical

60 Watt AC/DC converter for a portable medical instrument

  • High efficiency over very wide input voltage and load range
  • Mechanically rugged
  • Entire heat load contained in a sealed unit
  • Special input connector allows system to be washed down and disinfected without leaking or degrading

For this custom medical power supply, BEAR passed stringent testing requirements that the customer's offshore supplier had been unable to meet. See more information about our medical power supplies.

BEAR custom1.5W DC/DC converter smaller than sugar cube

1.5 Watt mini DC/DC converter for portable military communications system

  • 100VDC output
  • Wide operating temperature range: -55 to +85°C
  • High efficiency
  • Small size 0.5 x 0.5 x 0.4 inches (12.7 x 12.7 x 10.2 mm)

BEAR now offers this custom supply as a standard configurable product. See our DC/DC power supplies.

   

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